US12606919B2
Multi-metal electrocatalytic system for methane oxidation
Publication
Application
Classifications
IPC Classifications
CPC Classifications
Applicants
UTI Limited Partnership
Inventors
Md Golam Kibria, Tareq Ali Al-Attas, Mohd Adnan Khan, Nael Yasri
Abstract
Methods and cells are provided for electrochemically oxidizing methane to formate, in which methane supplied to an alkaline aqueous anolyte medium comprising hydroperoxyl anions is brought into contact with an oxidation catalyst anode. The oxidation catalyst may include CuFe oxide catalytic centres supported on a nickel substrate. An anodic current supplied to the oxidation catalyst in the anolyte medium electrolytically oxidizes methane to formate.
Figures
Description
FIELD
[0001]Innovations are disclosed in the field of oxidative electrochemical catalysis.
BACKGROUND
[0002]For decades, natural gas lagged coal and oil as an energy source, but today its consumption is growing rapidly as countries seek to lower greenhouse gas emissions by displacing coal for heating and power generation. The recent discoveries of vast shale gas reserves in the United States and widespread use of hydraulic fracturing, has seen natural gas prices decrease and today it supplies ˜22% of the global energy need.1 In its 2020 report, the International Energy Agency (IEA) projected global demand for natural gas to increase by 29% by 2040 and it would be the largest energy source among fossil fuels.2 In addition, the main component of natural gas i.e., methane (CH4) is a well-established and widely available feedstock to produce several important commodity chemicals such as methanol, hydrogen, ammonia, and formaldehyde. Typical valorization of CH4 takes place with a combination of steam methane reforming and Fischer-Tropsch synthesis. These are highly endothermic processes requiring high temperatures (700° C.-1100° C.), pressures (10-40 bars) and suffer from a tradeoff between conversion and selectivity. Moreover, they are highly capital-intensive processes, requiring many unit operations and centralized infrastructure, thus hindering their implementation on a small scale. Therefore, it seems of great importance to developing a low-cost sustainable method for the direct partial oxidization of CH4 to useful chemicals and fuels under ambient conditions.
[0003]In this context, electrochemical partial oxidation of CH4 to oxygenates such as methanol (CH3OH) and formic acid (HCOOH) is particularly attractive. The electrochemical conversion of CH4 under ambient conditions also offers a route to store renewable electricity addressing a major challenge of intermittency. The ability to control the potential to alter the selectivity of the reaction is another appealing factor to develop an electrochemical route for partial oxidation of CH4 to oxygenates. Since electrochemical devices are highly modular, and because the productivity scales directly with electrode size and current, an electrochemical route can provide an efficient and cost-effective solution that can be deployed in both large-scale industries and small-scale remote applications (such as those needed in remote oil fields).
[0004]There have been attempts to develop catalysts for electrochemical CH4 oxidation using metal/metal-oxides in various reaction conditions, however with limited success. The reported current densities or reaction rates are low (μA cm−2 to 1 mA cm−2), without any analysis of the Faradaic efficiency (FE) and reaction mechanism. A major difficulty arises due to the stable non-polar tetrahedral molecular geometry of CH4 and high C—H bond energy (ΔHC—H=439.3 KJ mol−1). Once this high activation energy for C—H bond dissociation is attained, it is difficult to control the partial oxidation to oxygenates, which are intermediate products, and avoid the terminal and more thermodynamically favourable pathway of CO2 production.3 The competitive oxygen evolution reaction (OER) poses additional challenges to attain high selectivity towards CH4 oxidation products. Conventional alkaline water electrolysers operate at room temperature, with the hydroxide ion (HO−) generally functioning as the oxidant. Nevertheless, HO− has a negligible activity for protons abstraction from CH4 at mild conditions.4 Attempts for electrochemical CH4 oxidation have also been made by utilizing high-temperature oxygen-ion conducting solid oxide electrolysis cells (SOECs). However, due to the use of high temperature, the reported selectivity towards oxygenates is negligible.
SUMMARY
[0005]Catalytic systems are disclosed for electrochemical CH4 oxidation to formate, including systems that function under ambient conditions. Operando spectroelectrochemistry studies reveal that the FeIV═O species are active sites for electrochemical CH4 oxidation. Although electrochemical oxidation of FeIII to FeIV can be achieved at high potentials (≥1.4 V versus reversible hydrogen electrode, VRHE), high overpotentials lead to overoxidation of CH4 to CO2. Therefore, we demonstrate herein the use of reactive oxygen species (e.g., generated via partial electrooxidation of H2O2 on Ni) to mediate FeIII oxidation to FeIV at lower overpotential, suppressing unwanted overoxidation. Furthermore, we reveal the key role of Cu as a co-catalyst in preventing the complete oxidation of CH4 to CO2 by increasing the activation energy of the intermediate step. A CuFeNi catalyst is accordingly provided that exhibits electrochemical CH4 oxidation to formate at high current density (32 mA cm−2), Faradaic efficiency (42%) and liquid oxygenate selectivity (100%) using a low applied potential (0.9 VRHE).
[0006]Methods for using electrolytic cells are accordingly provided for electrochemically oxidizing methane to formate. The methods involve providing a methane supply to an alkaline aqueous anolyte medium including hydroperoxyl anions, where the anolyte medium is in contact with an oxidation catalyst anode, where the oxidation catalyst anode includes CuFe oxide catalytic centres supported on a nickel substrate; and, supplying an anodic current to the oxidation catalyst anode in the anolyte medium, to electrolytically oxidize methane to formate in an anodic oxidation reaction.
[0007]Accordingly, one general aspect of the present methods and electrolytic cells involves the use of an anodic CuFeNi oxidation catalyst to electrochemically oxidize methane to formate, for example where the nickel substrate is a nickel foam substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
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[0012]
DETAILED DESCRIPTION
[0013]Selective partial oxidation of methane to liquid oxygenates has been a long-sought goal, due to the intrinsic chemical inertness of its C—H bonds. With the continuous reduction in renewable electricity prices, the electrochemical partial oxidation of methane is gaining momentum globally. Inspired by the catalytic sites in cytochrome P450 and soluble methane monooxygenase (sMMO) metalloenzymes, here we disclose a highly active multi-metal CuFeNi electrocatalyst for selective electrochemical methane oxidation reaction (eCH4OR) to formate at room temperature. Mechanistic studies using operando spectroelectrochemistry measurements revealed the synergistic effect of nickel, iron, and copper to selectively oxidize CH4. Specifically, the analysis revealed the presence of high valent FeIV as the active site for CH4 oxidation, attained by the reactive oxygen species generated during the partial oxidation H2O2 at low overpotentials compared to water oxidation reaction (OER) on nickel. Furthermore, the critical role of copper in preventing the overoxidation of valuable oxygenates to CO2 is disclosed. We achieved Faradaic efficiencies of ˜42% and liquid product selectivity of 100% at current densities of 32 mA cm−2 using a low applied potential of 0.9 V versus reversible hydrogen electrode. The system is schematically illustrated in
EXAMPLES
Electrochemical CH4 Oxidation Reaction (eCH4OR).
[0014]Electrochemical oxidations were performed in a 3-electrode H-type cell, in an alkaline environment (1.0 M KOH) using a hydrothermally grown CuFe oxide on nickel foam, denoted as CuFe/NiF (synthesis procedure is discussed in the Supplementary Information).
[0015]The current observed at a low potential regime (˜0.8-1.5 VRHE) is driven mainly from the H2O2 oxidation on the nickel surface. This was confirmed due to the negligible oxidation current (<1 mA cm−2) from CuFe catalysts which were grown on titanium foam (denoted as CuFe/TiF) following the same synthesis method as the CuFe/NiF electrode. Interestingly the current density with and without (i.e., Ar purge) purging CH4 did not change (
[0016]We then carried out chronoamperometry tests using the CuFe/NiF electrode with the addition of 50 mM H2O2, at different voltages, (
[0017]Further control experiment under open circuit potential (OCP) conditions, i.e., without an electrochemical bias, did not reveal any products via the 1H NMR analysis, indicating that the oxidation products detected (HCOO−+CO2) were directly/indirectly results of an electrochemical reaction. The CH4 oxidation was also conducted without the addition of H2O2 in the OER potential window.
[0018]The harsh oxidizing conditions warranted stability testing of our CuFe/NiF catalyst. We confirmed the stability of our catalyst by chronoamperometry measurements at 0.9 VRHE (
Catalyst Characteristics
[0019]X-ray diffraction (XRD) analysis was conducted to determine the crystallinity of the CuFe/NiF electrode. The XRD pattern (
[0020]X-ray absorption spectroscopy (XAS) was conducted to gain more understanding of the electronic and oxidation states of each element in the electrode. The XAS spectrum of the Fe L3-edge presents two main peaks at 708 and 711 eV while the Fe L2-edge shows peaks at 720 and 722 eV (
[0021]Further, the chemical state of the CuFe/NiF electrode was studied by X-ray photoelectron spectroscopy (XPS). The high-resolution spectrum of Fe 2p in
[0022]Field emission scanning electron microscopy (FE-SEM) images of the CuFe/NiF electrode illustrated the following characteristics. The synthesized CuFe consists of randomly interconnected compact nanoflakes covering the NiF substrate. Energy dispersive X-ray (EDX) spectroscopy proved the existence of Fe, Cu and O in the CuFe/NiF electrode with an atomic ratio for Cu/Fe at 1.65. This observation confirms that the CuFe composite is Cu-rich even though an equimolar amount of Cu and Fe precursors were used during the hydrothermal synthesis. A high-resolution transmission electron microscopy (HRTEM) image of the CuFe/NIF electrode is shown in
Mechanistic Study of eCH4OR
[0023]The control experiments as discussed earlier in
[0024]Upon adding H2O2, the same peak can be observed at 1.4 VRHE (˜ 600 mV lower overpotentials) with much higher intensity (
[0025]The mechanisms of C—H bond dissociation of CH4 can be classified into two categories: dehydrogenation and deprotonation. The dehydrogenation mechanism is generally observed for strong oxidizing catalysts such as high-valent metal oxo species as in the FeIVv=O.20 The mechanism occurs via the surface nucleophilic oxygens, i.e., electron saturated species (O2−), which act as H+ acceptors and abstract a hydrogen atom (·H) from CH4. In contrast, the deprotonation mechanism usually occurs on metal complexes with low oxidation states metal centres and accessible H+ acceptors.21 In addition to the dehydrogenation and deprotonation mechanisms, CH4 oxidation could go through the Fenton pathway in which the reaction is initiated by free radicals that are accompanied by a Fenton reagent, such as FeII which generates ·OH radicals. A DFT study by Szécsényi et al. have shown the existence of a combination of dehydrogenation, deprotonation, and Fenton pathways.21 The complexity of their reaction mechanism is due to the presence of multiple oxidation states of Fe. It has been found that FeII and FeIII favour the deprotonation and Fenton pathways, while the FeIV═O would promote the dehydrogenation pathway.20 Adopting electrochemical means assure steady generation of FeIV sites that can prevent unwanted competing reactions at the FeIII sites to take place through the Fenton pathway.20
[0026]These high valent FeIV species detected during in situ spectroelectrochemical measurements of
[0027]
[0028]Therefore, even without the use of H2O2, one can generate the high-valent metal oxo FeIV═O species, and in return dissociate the C—H bond. However, due to the use of high voltages, there will be a competitive OER, in addition to the high possibility of the produced oxygenates being overoxidized to CO2. This supports what was observed during the electrochemical tests discussed in
[0029]
[0030]Hence, FeIV═O would easily be formed since H2O2 oxidation happens at low applied potential compared to H2O oxidation. The copper centres will modulate the reaction environment and prevent the over-oxidation of the produced oxygenates to CO2 by reducing the excess of radicals.
CONCLUSION
[0031]A route for selective partial oxidation of methane at ambient conditions is disclosed herein, which avoids unwanted overoxidation to CO2. Operando potential-controlled spectroelectrochemistry showed that FeIV can be obtained with the help of reactive oxygen species generated via the partial electrooxidation of H2O2 at lower overpotentials. Cu is disclosed to have a crucial role in protecting the produced liquid oxygenates from overoxidation to CO2. A trimetallic catalyst of CuFeNi is provided that is demonstrated to be capable of Faradaic efficiencies of ˜42% and liquid product selectivity of 100% at current densities of 32 mA cm−2.
[0032]Although various embodiments of the invention are disclosed herein, many adaptations and modifications may be made within the scope of the invention in accordance with the common general knowledge of those skilled in this art. Such modifications include the substitution of known equivalents for any aspect of the invention in order to achieve the same result in substantially the same way. Numeric ranges are inclusive of the numbers defining the range. The word “comprising” is used herein as an open-ended term, substantially equivalent to the phrase “including, but not limited to”, and the word “comprises” has a corresponding meaning. As used herein, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a thing” includes more than one such thing.
[0033]Citation of references herein is not an admission that such references are prior art to the present invention. Any priority document(s) and all publications, including but not limited to patents and patent applications, cited in this specification are incorporated herein by reference. All documents cited or referenced in herein cited documents, together with any manufacturer's instructions, descriptions, product specifications, and product sheets for any products mentioned herein or in any document incorporated by reference herein, are hereby incorporated herein by reference, and may be employed in the practice of the invention. More specifically, all referenced documents are incorporated by reference to the same extent as if each individual publication were specifically and individually indicated to be incorporated by reference herein and as though fully set forth herein. The invention includes all embodiments and variations substantially as hereinbefore described and with reference to the examples and drawings.
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Claims
The invention claimed is:
1. A method for electrochemically oxidizing methane to formate, comprising, in an electrolytic cell:
providing a methane supply to an alkaline aqueous anolyte medium comprising hydroperoxyl anions, wherein the alkaline aqueous anolyte medium is in contact with an oxidation catalyst anode, wherein the oxidation catalyst anode comprises CuFe oxide catalytic centres supported on a nickel substrate; and,
supplying an anodic current to the oxidation catalyst anode in the alkaline aqueous anolyte medium, to electrolytically oxidize methane to formate in an anodic oxidation reaction.
2. The method of
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